Sawn Craft Zero 32 User guide

Revised 2016-04-18
Zero 32
Assembly and Setup Manual
Specifications
Recommended Power System
Wingspan
32”
ESC
10A Brushless
Overall Length
31.9”
Motor
100 watt out runner (24g)
Wing Area
233.7 in2
Servo
4x 5g Micro
Flying Weight
8.2oz / 235g
RX
6-Channel (4-ch minimum)
Intended Use
Indoor/Outdoor
Battery
450mAh 3S 11.1V 25C LiPo (or similar)

Thank you from Sawn Craft.
Thank you for purchasing the Sawn Craft Zero 32 aircraft kit, the first 32" offering in our Front Yard
Fighters Series! Like the full-scale A6M Zero, in your hands is a remarkably versatile airplane designed to
deliver a pleasure cruiser with an incredible look in the air. The lightweight and resilient EPP and carbon
construction makes it possible for you to experience a wide performance envelope. This means that no
matter how you like to fly, you’ll enjoy both stability and maneuverability without any sacrifice in
precision or control feel.
Your Sawn Craft Zero 32 aircraft kit represents the benchmark of indoor flight performance and
aerobatic versatility. All you have to do next is read and apply the information presented in this
instruction manual.
I sincerely hope that you enjoy your model as much as we do! If you have any troubles with these
instructions or in the setup of your model feel free to contact us and we will provide you with the
service you expect from a hobbyist-owned and operated business.
Jonathan Sawn
Owner, Sawn Craft
[email protected]om

TableofContents
1 Introduction 1
1.1 Style Conventions 1
1.2 Required Tools & Supplies 1
1.3 Required Parts for Completion 2
1.4 Included Parts Description 3
2 Assembly Instructions 4
2.1 Parts Sheet Removal 4
2.2 Fuselage Components Assembly 5
2.3 Control Surface Hinging 6
2.4 Lower Component Assembly 8
2.5 Landing Gear Assembly 9
2.6 Upper Vertical Fuselage Installation 10
2.7 Electronics Installation 11
2.8 Gusset Installation 15
2.9 Painting/Decorating 16
3 Setup and Tuning 17
3.1 Center of Gravity 17
3.2 Radio Setup and Mixing 17
3.3 Control Throws and Expo 18
3.4 Launching/Take-Off 18
3.5 Flying Tips 18
3.6 Repairs & Spare Parts 19

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1
1 Introduction
NOTE: This manual is available on Sawn-Craft.com under the Support tab. Once there, you can view and
print this manual in a larger size at your convenience.
The contents of this manual assume the operator will have the following prerequisites:
Understanding of all appropriate safety procedures and requirements
The ability to follow written procedures and possess basic hobby building skills
1.1 Style Conventions
Below are the important style conventions that will be used throughout the guide.
Note: Key points or hints for success will be formatted in this manner.
Warning: Any area that poses either a physical hazard or the danger will be formatted in this manner.
Arrows inform where to click or to perform the specified operation.
Circled items inform of items of interest for the specified operation. Circled items will typically be
accompanied by text further identifying the region of interest.
1.2 Required Tools & Supplies
The list below contains all of the required tools and supplies that are required for the assembly and
tuning of this model.
Clean, flat work surface (building board)
#11 hobby knife or other razor knife
with spare blades
2x Metal straight-edge ruler
T-Pins (1” – 1.5” are ideal)
Scissors
Marker
Drill w/ 1/16” & 5/64” bit
Beacon Foam-Tac foam-safe adhesive
CA adhesive
Masking tape
Wax paper
Soldering iron & solder
Heat gun
Wire cutters
Needle nose pliers

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Sawn Craft recommends the use of Beacon Foam-Tac adhesive for the construction of this model due
to its strength, light weight, and easy use. Foam-Tac can be purchased by visiting the Building
Supplies tab on Sawn-Craft.com
1.3 Required Parts for Completion
The list below contains the tested and recommended parts for your model:
Sawn Craft FYF Completion Kit - Large
oHextronik 24g 1300kv motor
o10A Brushless ESC
o4x 5g Servos
o6-Channel Receiver (Optional)
o8”x4” Electric Prop
oJST Female Pigtail
oShrink tube, etc.
460mAh 3S 25C LiPo Battery
Velcro
Please note that other power systems and components may be compatible and may work without
issue, but the listed components have been used successfully by Sawn Craft.
The order of assembly presented in this instruction has been tested and it is recommended that you
do not differ from them to provide the most accurate and easiest assembly possible. Also, the
construction techniques of many of our aircraft are extremely similar. Though we will try to include
as many photos of your specific kit in this instruction, other kit assembly photos may be used if the
instruction and “look” of the assembly is the same.

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1.4 Included Parts Description
Please inspect your kit and ensure that all listed parts are present and undamaged. If you find missing
parts or signs of damage please contact [e-mail] for assistance.
a) 30” Carbon Strip
b) Rudder
c) Elevator Half (2 each)
d) Wing (2 each)
e) Aileron (2 each)
f) 3mm EPP Gussets (4 each long half, 2 each short)
g) Lower Vertical Fuselage Front
h) Lower Vertical Fuselage Rear
i) Horizontal Fuselage Front
j) Horizontal Fuselage Middle
k) Horizontal Fuselage Rear
l) Upper Vertical Fuselage Front
m) Upper Vertical Fuselage Middle
n) Upper Vertical Fuselage Rear
o) Small Parts Bag:
o.1 35mm Wheel (2 each)
o.2 9” Carbon Strip
o.3 7” Carbon Rod (3 each)
o.4 3” Carbon Rod
o.5 Plywood Motor Mount
o.6 Plywood Control Horns (4 each)
o.7 Wire Control Rods (4 each)
o.8 Micro Linkage Stoppers (4 each)
o.9 24” Landing Gear Binding Thread
e
g
d
i
f
j
b
a
k
1
2
3
4
5
6
7
9
8
c
c
h
n
m
l

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2 AssemblyInstructions
2.1 Parts Sheet Removal
Parts Required:
oKit Parts Sheets
1) Using a sharp hobby knife carefully cut the foam parts out of the sheets. The small tabs holding
the parts into the sheet can sometimes be tricky to find so if you have trouble removing a part
from the sheet keep looking for that last tab. Once out of the sheet, you may choose to clean up
the remaining tab on the foam pieces with some sandpaper.
2) Find and mark with masking tape the bottom of the horizontal fuselage, bottom of the wing halves,
bottom of the ailerons, and bottom of the elevator. The bottom of these components will have a
slot milled for carbon strips. Find and mark with masking tape the LEFT side of the rudder and the
LEFT side of upper component of the vertical fuselage. These labels will help to assure the beveled
hinge cuts are on the correct side of the foam.
Note: Looking at the bottom
side of the Elevator
components, the control horn
slot should be to the left.
Looking at the bottom side of
the Horizontal Fuselage, the
cut-out for the elevator servo
should also be located to the
left.

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2.2 Fuselage Components Assembly
Parts Required:
oHorizontal Fuselage Nose, Middle, & Tail
oUpper Vertical Fuselage Nose, Middle, & Tail
oLower Vertical Fuselage Nose & Tail
o3mm Long Gusset Halves
1) Using Foam-Tac, glue the Horizontal Fuselage Nose, Middle, & Tail pieces together to form the
completed Horizontal Fuselage.
2) Glue the Upper Vertical Fuselage Nose, Middle, & Tail pieces together to form the completed
Upper Vertical Fuselage.
3) Glue the Lower Vertical Fuselage Nose & Tail together to form the completed Lower Vertical
Fuselage.
4) Glue the one 3mm Long Gusset half to its mating other half to form a completed 3mm Long
Gusset. Repeat this process for the other 3mm Gusset halves.
Attach here after
removed from sheet

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2.3 Control Surface Hinging
Parts Required:
oHorizontal Fuselage
oUpper Vertical Fuselage
oWing (2x)
oAileron (2x)
oRudder
oElevator
5) Bevel the hinged control surfaces (ailerons, rudder, & elevator) along the bottom edge of the
ailerons and elevator and down the left side of the rudder, using steel rulers and fresh single-edge
razor blades. Set a 12-inch or longer metal ruler backing at the edge of your workbench. Lay the
foam part to be beveled on the ruler, aligning the edge of the ruled and the edge of the foam
nearest to you. Lay a second steel ruler facing down far enough back to expose enough foam to
allow a 45 degree slice to be removed. Cut the foam with the single-edge razor blade held against
both rulers. Angling the blade makes a smoother cut.
EPP foam dulls blades surprisingly fast, so be prepared to change to a fresh blade when you detect
snagging or excess drag as you make your cuts!

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6) Make glue hinges. Pin to the building board each of the hinged parts, with bevel cut down against
the building board. Locate the parts with the mating surfaces gently touching. Run the smallest
possible bead of foam glue along each seam. Run a finger along each seam to push the glue
between the mating parts. Blot up excess glue with a paper towel. Let dry at sufficiently for the
glue to fully cure. Leaving the parts overnight is ideal for the strongest and most true bond.
BUILDING TIP: Keep small wipes handy to remove excess glue. Glue outside the joint adds weight, but
does not add strength. To get a pile of these wipes, lay four paper towels together and cut in half
repeatedly. Four paper towels cut to roughly 2x2 inch squares yields 64 very handy "micro wipes."